Checking and adjusting the clearances in the valve drive is carried out on a cold engine (at coolant temperature: 20°C and cylinder head mounted on the engine.
Pic. 2.100. Camshaft valve drive
Remove the engine noise cover.
Remove the oil filler cap.
Loosen the center cover bolts and then remove the cover.
Pic. 2.101. Upper Timing Belt Cover
Remove the timing belt top cover (pic. 2.101).
Loosen the bolts securing the upper timing belt cover and then remove the cover.
Remove the cylinder head cover.
Disconnect the high voltage spark plug wires by holding them by the caps and not applying much force when disconnecting them.
Note. Pulling or bending a high voltage wire can damage the conductor inside the wire.
Disconnect the positive crankcase breather hose and the positive crankcase breather valve hose from the cylinder head cover.
Disconnect the accelerator pedal cable from the cylinder head cover.
Turn away bolts of fastening of a cover of a head of cylinders and then remove a cover and a lining.
Pic. 2.102. Installing the piston of cylinder No. 1 at TDC of the compression stroke
Set the piston of cylinder No. 1 to TDC of the compression stroke (pic. 2.102).
Turn the crankshaft pulley and align the groove on it with the alignment mark «T» on the injection advance angle indicator (scale on the bottom cover of the timing belt).
Pic. 2.103. Aligning the camshaft sprocket with the alignment mark on the front bearing cap
Check that the hole in the sprocket (for belt) camshaft is aligned with the alignment mark on the front camshaft bearing cap. If there is no alignment, then turn the crankshaft one turn (360°) (pic. 2.103).
Check valve clearances.
Check only the valves marked in the figure (when the #1 piston is at compression TDC). Measure the valve clearance.
Using a feeler gauge, measure the clearance between the valve lifter shim and the rear (non-working) cam parts.
Write down the results of the clearance measurements at the places where the measured value does not correspond to the allowable values. This data will be required later for the selection of a replacement shim.
Valve clearance values (at engine coolant temperature: 20°С) are listed below.
Rated value:
- intake valves - 0.20 mm;
- exhaust valves - 0.28 mm.
Maximum allowable value:
- intake valves - 0.12–0.28 mm;
- exhaust valves - 0.20–0.36 mm.
Adjustment of gaps in the valve drive when the piston of cylinder No. 1 is at TDC of the compression stroke
Rotate the crankshaft pulley one turn (360°) and align the groove on it with the alignment mark «T» on the injection advance angle indicator (scale on the bottom cover of the timing belt).
Pic. 2.104. Checking clearances in the valve drive when the piston of cylinder No. 1 is at TDC of the compression stroke
Check only the valves marked in Figure 2.104 when the piston of cylinder No. 4 is at TDC compression. Measure the valve clearance.
Pic. 2.105. Checking clearances in the valve drive when the piston of cylinder No. 4 is at TDC of the compression stroke
Adjustment of clearances in the valve drive when the piston of cylinder No. 4 is at TDC of the compression stroke
Adjustment of clearances in the intake and exhaust valves.
Pic. 2.106. Installing the camshaft cam
Rotate the crankshaft so that the clearance-adjustable valve has the protruding part of the camshaft lobe pointing up (pic. 2.106).
Pic. 2.107. Installation of a stopper between a camshaft and a pusher of the valve
Using special tool 09220-2D000, press the valve lifter and insert the stopper between the camshaft and the valve lifter. Remove special tool (pic. 2.107).
Pic. 2.108. Removing the shim
Using a small screwdriver and a magnet, remove the shim (pic. 2.108).
Pic. 2.109. Shim measurement
Using a micrometer, measure the thickness of the removed shim (pic. 2.109).
Calculate the thickness of the new shim that must be installed so that the valve actuator clearance matches the nominal value.
Valve clearance (at engine coolant temperature: 20°С)
T: Thickness of installed shim
A: Measured clearance in the valve actuator.
N: Thickness of the new shim.
- Inlet valve: N=T+ (A–0,20) mm.
- Exhaust valve: N=T+ (A–0,28) mm.
Select a new shim thickness as close to the calculated value as possible.
Note. There are 20 valve lifter shim sizes in 0.04mm increments ranging from 2.0mm to 2.76mm.
Install the selected shim on the valve lifter.
Using special tool 09220-2D000, press the valve lifter and remove the stopper.
Check the clearance in the valve actuator again.
Installation
Remove the remnants of the old gasket and sealant from the mating surfaces of the cylinder head and cylinder head cover.
Pic. 2.110. Places for applying sealant to the cylinder head cover
Apply sealant (Loctite № 5999) on the cylinder head cover (pic. 2.110).
Install the cylinder head cover.
The moment of an inhaling of bolts of fastening of a cover of a head of cylinders: 8–10 Н·м.
Connect the accelerator pedal cable.
Connect the positive crankcase breather hose and the positive crankcase breather valve vent hose to the cylinder head cover.
Connect the high voltage spark plug wires to the spark plugs.
Install the timing belt top cover and tighten the four mounting bolts.
Install the center cover and tighten the five mounting bolts.
The moment of an inhaling of bolts of fastening of the central cover: 2,5–3,5 Н·м.
Install the oil filler cap.
Install the engine noise cover.
Timing chain guide
Pic. 2.111. Chain guide
Check the chain guide for kinks, cracks or other defects (pic. 2.111).
Check the chain guide rubber pad for excessive wear.
Replace the chain guide if necessary.
Pic. 2.112. Timing chain
Timing chain check
Check circuit elements (bushings and plates) for no wear. Replace chain if wear is excessive.
Installation
Install the hydraulic lifters in place.
Pic. 2.113. Alignment of the timing chain with the chain sprockets of the intake and exhaust camshafts
Align the timing chain with the chain sprockets of the intake and exhaust camshafts, as shown in Figure 2.113.
Pic. 2.114. Installation of camshafts
Lubricate the camshaft bearing journals with engine oil, then install the camshaft in place (pic. 2.114).
Pic. 2.115. Identification marks on bearing caps
Install the camshaft bearing caps. The identification marks on the bearing caps are used to identify the location of the cap installation (intake/exhaust valve side) (pic. 2.115).
- I: intake camshaft.
- E: exhaust camshaft.
Pic. 2.116. The order of tightening the bolts of the camshaft bearing caps
Tighten bolts of fastening of covers of bearings of camshafts the nominal moment of an inhaling in two-three receptions in the order specified by numbers in drawing 2.116.
The moment of an inhaling of bolts of fastening of a cover of the bearing of a camshaft: 12–14 Н·м.
Pic. 2.117. Pressing the camshaft oil seal with a special tool
With a special tool (mandrel for installing the camshaft oil seal 09221-21000) press in the camshaft seal (pic. 2.117).
Make sure the lip of the camshaft oil seal is lubricated with engine oil. Slide the oil seal onto the camshaft from the timing belt sprocket side, then tap the mandrel with a hammer to install the oil seal so that it is flush with the surface.
Pic. 2.118. Camshaft sprocket installation
Set the sprocket (for belt) camshaft and tighten the bolt of its fastening with the nominal tightening torque (pic. 2.118).
Tightening torque of the camshaft sprocket bolt (for belt): 80–100 Nm.
Align the marks on the crankshaft and camshaft sprockets with the corresponding alignment marks and set the No. 1 cylinder piston to TDC on the compression stroke.
Install the cylinder head cover.
The moment of an inhaling of bolts of fastening of a cover of a head of cylinders: 8–10 Н·м.
Install the ignition coil assembly, high voltage spark plug wires and center cap.
Pic. 2.119. Timing belt installation
Install the timing belt, and then when the tensioner roller tensions the belt, tighten the tensioner fastener (pic. 2.119).
Install the timing belt covers.
Tightening torque of the timing belt cover bolts: 8–10 Nm.
Install the water pump pulley and crankshaft pulley.